3bse056248 en Ac 800m and s800 i o - Getting Started

IndustrialITAC 800M and S800 I/O

Getting Started

NOTICEThis document contains information about one or more ABB products and may include adescription of or a reference to one or more standards that may be generally relevant tothe ABB products. ABB may have one or more patents or pending patent applicationsprotecting the intellectual property in the ABB product(s) described in this publication.The presence of any such description of a standard or reference to a standard is not arepresentation that all of the ABB products referenced in this document support all of thefeatures of the described or referenced standard. In order to determine the specific fea-tures supported by a particular ABB product, the reader should consult the product spec-ifications for the particular ABB product.

The information in this document is subject to change without notice and should not beconstrued as a commitment by ABB. ABB assumes no responsibility for any errors thatmay appear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequentialdamages of any nature or kind arising from the use of this document, nor shall ABB beliable for incidental or consequential damages arising from use of any software or hard-ware described in this document.

This document and parts thereof must not be reproduced or copied without written per-mission from ABB, and the contents thereof must not be imparted to a third party nor usedfor any unauthorized purpose.

The software or hardware described in this document is furnished under a license andmay be used, copied, or disclosed only in accordance with the terms of such license.

This product meets the requirements specified in EMC Directive 89/336/EEC and in LowVoltage Directive 72/23/EEC.

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Copyright © 2003-2009 by ABB. All rights reserved.

Release: March 2009Document number: 3BSE056248

TABLE OF CONTENTS

About This BookGeneral ..............................................................................................................................7

Document Conventions .....................................................................................................7

Warning, Caution, Information, and Tip Icons..................................................................7

Related Documentation .....................................................................................................8

Section 1 - Product OverviewCentral Processing Unit (CPU) .......................................................................................10

Communication Interface ................................................................................................12

S800 I/O...........................................................................................................................12

Section 2 - InstallationMounting AC 800M and S800 I/O Units onto DIN-Rail ................................................15

Mechanical Installation - Metal Sheet..................................................................15

Mechanical Installation - Prefabricated Aluminum Profile .................................17

Mounting and Removing PM8xx, CI8xx and S800L Units ............................................18

Mounting and Removing S800 I/O Units........................................................................20

Power Supply...................................................................................................................26

Section 3 - ConfigurationController Configuration - Basic Rules and Examples ...................................................27

S800 I/O Configuration - Basic Rules and Examples .....................................................32

3BSE056248 5

Table of Contents

Section 4 - OperationHardware Indicators ........................................................................................................43

AC 800M Controller (PM8xx) ............................................................................43

LED Indicators..................................................................................................... 43

Switches and Push Buttons ..................................................................................45

Communication Interface LEDs .......................................................................... 45

S800 I/O Module LEDs .......................................................................................46

S800L I/O Module LED ...................................................................................... 49

Start Modes .....................................................................................................................52

Section 5 - Maintenance/Replacement of Faulty UnitsOnline Replacement of Unit............................................................................................ 53

Appendix A - IndustrialIT System 800xA AC 800M Controller - Data Sheet ............................................................... 55

Appendix B - System 800xA S800 I/O System - Data Sheet...... 59

Appendix C - Dimensions............................................................................... 65

6 3BSE056248

About This Book

GeneralThis manual is intended to give the reader a general knowledge about AC 800M, S800 I/O and S800L hardware. It includes a general product overview, guidance for installation, configuration examples, information valuable during operation and maintenance considerations. Several other manuals forms the complete documentation of AC 800M, S800 I/O and S800L hardware which are listed in the subsection Related Documentation. However, this manual should give all needed knowledge to get started with the use of the hardware.

Document ConventionsMicrosoft Windows conventions are normally used for the standard presentation of material when entering text, key sequences, prompts, messages, menu items, screen elements, etc.

Warning, Caution, Information, and Tip IconsThis publication includes Warning, Caution, and Information where appropriate to point out safety related or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols should be interpreted as follows:

Electrical warning icon indicates the presence of a hazard which could result in electrical shock.

Warning icon indicates the presence of a hazard which could result in personal injury.

3BSE056248 7

Related Documentation About This Book

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process performance leading to personal injury or death. Therefore, fully comply with all Warning and Caution notices.

Related Documentation

Caution icon indicates important information or warning related to the concept discussed in the text. It might indicate the presence of a hazard which could result in corruption of software or damage to equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to use a certain function

Document ID Title

3BDS009029Rxxxx IndustrialIT 800xA - Control and I/O, PROFIBUS DP, Wiring and Installation

3BSE020923Rxxxx IndustrialIT 800xA - Control and I/O, S800 I/O, General Information and Installation

3BSE020924Rxxxx IndustrialIT 800xA - Control and I/O, S800 I/O, Modules and Termination Units

3BSE020927Rxxxx IndustrialIT 800xA - Control and I/O, S800 I/O, Modules and Termination Units with Intrinsic Safety Interface

3BSE036351Rxxxx IndustrialIT 800xA - Control and I/O, AC 800M Controller Hardware, Hardware and Operation

3BSE041880Rxxxx IndustrialIT 800xA - Control and I/O, Getting Started, Introduction and Basic Operation

8 3BSE056248

Section 1 Product Overview

The AC 800M controller consists of a selection of units mounted on horizontal DIN-rails, which can be housed within an enclosure. The majority of units consist of a base mounting plate and a removable module attached with screws.

The hardware units that form the AC 800 M controller are:

• Central Processor unit (CPU)

• Communication interface modules for different protocols

• S800 I/O modules

• Power supply modules

Various I/O systems can be connected to the AC 800M controller, either directly (S800 I/O) or via PROFIBUS or FOUNDATION.

Figure 1. Example of an AC 800M Controller with an S800 I/O Unit

3BSE056248 9

Central Processing Unit (CPU) Section 1 Product Overview

Central Processing Unit (CPU)The CPU consist of a base plate TP830 (Terminal Plate) and a processor module PM8XX with various speed and memory combinations.

The base plate TP830 carries the majority of the connections to processor, the power supplies and communication interfaces, as well as to external buses.

CPU Base plate

Internal battery cover

ModulebusSocket

Power Supply

CEX-BusSocket

Fuse

10 3BSE056248

Section 1 Product Overview Central Processing Unit (CPU)

Figure 2. Processor Unit - General View (here shown with PM861)

Tx/Rx Optical ModuleBus

External BatterySupply Socket

Power SupplyandSupervision SignalSocket (SS822/SS823)

COM3/COM4PortsDIN-rail

Locking Device

CN1/CN2Ports

Tx/RxStatus

INITPush button

LEDStatus

Indicators

Indicators

RCU LinkConnector(PM861/PM864/ Electrical

ModuleBus

CEX-Bus

PM865)

Compact Flash slot

CF Connector

Lugs for extra screws to providesecure mounting in locations subjectto vibration

3BSE056248 11

Communication Interface Section 1 Product Overview

Communication InterfaceA number of communication modules can be connected to the controller. See Appendix A, IndustrialIT System 800xA AC 800M Controller - Data Sheet for more information on the various modules.

Communication Interface connected with CEX bus:

Up to 12 communication units can be placed on Communication Expansion Bus (CEX) bus.The CEX bus must be terminated if a communication unit is connected. A CEX bus termination is delivered with the e CPU: tb850 (male) or TB851 (female).

An extension cable TK850 with connector DB25P with metal housing and a length of 0.7meter (1.3') can be used for extending the CEX bus to a second din rail.

S800 I/OS800 I/O is a distributed and modular I/O system that communicates with controllers over PROFIBUS-DP/DPV1 or direct (via Modulebus).

The S800 I/O system is DIN rail mounted and consists of Fieldbus Communication Interfaces, Modulebus Modems, S800 I/O modules and Module Termination Units (MTU). S800 I/O modules (not S800L) are mounted on MTU's, this makes them hot-swappable. Depended on the mounting requirement (horizontal or vertical) and on the field termination needs (powering, fusing etc.) there are numerous of MTU's to choose from.

The S800 I/O system supports fully redundant applications, redundancy can be built in on both communication level and I/O module level.

S800 I/O connected with PROFIBUS- DP/DPV1:

• Field Communication Interface CI801 or CI840 is the I/O station master

• Maximum 24 I/O modules per I/O station

• 1 base I/O cluster with up to 12 I/O modules (connected via electrical Modulebus)

• 1-7 additional I/O clusters with up to 12 I/O modules per cluster (connected via optical Modulebus using Modulebus Modems)

12 3BSE056248

Section 1 Product Overview S800 I/O

S800 I/O connected with Modulebus:

• Connection via Electrical Modulebus (single controller only)

– Up to 12 I/O modules

• Connection via Optical Modulebus

– 1-7 I/O clusters with up to 12 I/O modules per cluster (connected using Modulebus Modem TB820 or TB840A)

PM851 is restricted to one optical Modulebus cluster.

3BSE056248 13

S800 I/O Section 1 Product Overview

14 3BSE056248

Section 2 Installation

Mounting AC 800M and S800 I/O Units onto DIN-RailAC 800M and S800 I/O units are DIN-rail mountable. Each unit has a DIN rail locking mechanism that achieve mechanical locking and effective grounding. The additional screw lugs, located in the lower part of the units are used to provide extra fastening in environments subject to excessive vibrations. AC 800M units (CPU and communication interfaces) must be mounted on horizontal DIN rails. S800 I/O units can be mounted on both horizontal and vertical DIN rails.

There are two ways of mounting AC 800M and S800 I/O in cabinets, open rack or other types of installations:

• Mounting on DIN rail attached to a metal sheet

• Mounting on prefabricated aluminium profile with DIN rail

All conductive structural components of the installation must be bonded together with good and permanent connections for electrical safety and EMC reasons. The bonding should preferably be made with self-tapping cutting head screws. On painted surfaces where fastening is done by screw and nut, the paint must be removed from the contact surfaces. Apply conductive grease on surfaces to ensure a permanent connection. The cabinet/rack shall be properly connected to protective earth/ground.

Mechanical Installation - Metal Sheet

The DIN-rail is mounted on an unpainted metal sheet with fastening screws every 100 mm to ensure good mechanical stability and a good chassis ground connection in the cabinet or an open rack, see Figure 3.

3BSE056248 15

Mechanical Installation - Metal Sheet Section 2 Installation

The metal sheet shall at least be 2.5 mm thick and at least 180 mm high with preferably one side bend 90 degrees to increase the stability. The metal sheet shall be mechanically fastened at least every 500 mm to the cabinet or rack with a minimum of four screws. The fastening to the cabinet frame shall be performed with self-tapping screws to get a good grounding connection.

DIN-rail type with height 7.5 mm shall be used. Refer to type NS 35/7.5 according to standard EN50022.

Figure 3. Mechanical Installation

100 100 100 100

DIN-ra il 450 mm

70

178

266

Al ternative anchoring of e.g. I/O cables in appropria te cable duct

Alte rnati ve anchoringof exceptional cables.Use cable suppor t bar+ insulating layer+ str aps

DIN-ra il (he ight 7, 5 mm) mounted w ith

End support 2 x 3BSC022471R1

tapping screws M6x10

Ensure good electrical contact to chassiesFor al l bolted joints

Tapping screws with scratches M6x10

16 3BSE056248

Section 2 Installation Mechanical Installation - Prefabricated Aluminum Profile

Mechanical Installation - Prefabricated Aluminum Profile

There are aluminum profiles for horizontal and vertical mounting. The aluminum profile gives an excellent grounding and rigid mounting of products concerned. The aluminum profile shall be fastened to the cabinet with at least 4 self-tapping screws.

The profile has grooves for screws that can be used for fastening the modules in an environment with excessive vibrations.

The aluminum profiles have one DIN-rail and one cable duct.

Figure 4. Cabinet with Controller and I/O on metal sheet

3BSE056248 17

Mounting and Removing PM8xx, CI8xx and S800L Units Section 2 Installation

The aluminum profiles are available in different sizes. For horizontal mounting use 3BSE022255R1 (465 mm, 19") or 3BSE022256R1 (592 mm, 24") or 3BSE022257R1 719 mm, 28.31"). For vertical mounting use 3BSE049768R1 (1800 mm, 71").

Mounting and Removing PM8xx, CI8xx and S800L UnitsBefore mounting any processor unit or communication interface onto the DIN-rail, read carefully the installation instructions provided with the equipment. Since the electronic unit and base plate are supplied as a single unit, there is no requirement to separate them during the mounting procedure.

Mounting the units onto the DIN-rail only requires a blade screwdriver that fits securely into the locking screw (1 mm slot).

Figure 5. Cabinet with Controller on prefabricated aluminium profiles

18 3BSE056248

Section 2 Installation Mounting and Removing PM8xx, CI8xx and S800L Units

Figure 6. Base plate Locking Device

It is not allowed to manipulate CEX bus base plates in a powered and running system. Before changing or removing a base plate, all CEX modules on that segment must be removed.

To prevent damage to the pins, be sure the base plate plugs and sockets are fully aligned as the units interconnect. Under no circumstances use excessive force.

It is essential that the locking device is placed in the LOCKED position to avoid possible problems caused by vibration and/or intermittent grounding.

1 . OPEN 2. SLIDE 3. LOCKED

3BSE056248 19

Mounting and Removing S800 I/O Units Section 2 Installation

When disconnecting units from each other, use a screw driver according to Figure 7

Mounting and Removing S800 I/O UnitsThe S800 I/O is mounted on a standard DIN-rail according to EN 50022 NS35/7,5. The DIN-rail is mounted in a cabinet or on an enclosure wall to a metal sheet with fastening screws every 100 mm to ensure a good chassis ground connection in the cabinet or an open rack. The ModuleBus master, ModuleBus Modem, MTUs and S800L I/O modules are mounted to the DIN rail. In environments with major vibrations, the MTUs shall also be screwed on the metal sheet. The FCI, ModuleBus Modem and MTUs have a snap locking device that attaches it to the mounting rail.

It is possible to mount the FCI, ModuleBus Modem, MTUs and S800L I/O modules both vertically and horizontally.

Figure 7. Separating the Base Plates

F

RRx/Tx

RTS

F

RRx1

Tx1

Rx2

Tx2

CI853

COM1 COM2

F

RP

INIT

B

PM860

CN1 CN2 COM3 COM4

CI851

20 3BSE056248

Section 2 Installation Mounting and Removing S800 I/O Units

To mount the FCI, ModuleBus Modem or MTU, place it on the top edge of theDIN rail, release the rail latch with a flat blade screw driver and snap the bottom mechanism into place. When the unit is in place on the DIN rail and in position, take away the screw driver and the rail latch will fix the unit in position on the DIN rail. Release the unit from the DIN rail in a similar way.

A flat blade screw driver can be used to release the latch to allow easier movement along the DIN rail or removal of the unit (Figure 8).

Figure 8. MTU Latching System

A

BC

D

E F

A

BC

D

E F

Move up torelease rail latch

GroundClip Spring

DIN-railI/O ModuleLock/Switch

Pry down torelease rail latch

To

Lock

C1 2 3 4 5 6 7 C8 L2+L1+

B1 2 3 4 5 6 7 B8 L2+L1+

A1 2 3 4 5 6 7 A8 L2-L1-

3BSE056248 21


Snapping the FCI, ModuleBus Modem or MTU to the DIN-rail makes contact by a grounding spring with the chassis.

Connection of the MTU, or S800L module, ModuleBus connector to the FCI, ModuleBus Modem, next MTU or S800L module is made by sliding the MTU or the S800L module along the mounting rail and then locking it in place (Figure 9).

Figure 9. I/O Station Installation Diagram

A

BC

DE F

A

BC

D

E F

STN. ADDR.

SBSA

L-L+ L+

L-

SH

+

-

F R

T2T1

P

SH

+

-

SH

SH

SERVICE

CI810

012

9

75

38

4 6

012

9

75

38

4 6

x 10

x 1

AF100

A

BC

D

E F

A

BC

D

E F

C1 2 3 4 5 6 7 C8

B1 2 3 4 5 6 7 B8

A1 2 3 4 5 6 7 A8

L1+ L2+

L2-L1-

L2+L1+Tx

Rx

Tx RxSWX.X/Y

21

A1 2 3 4 5 6 7 A8 L2-L1-

B1 2 3 4 5 6 7 B8L1+ L2+

C1 2 3 4 5 6 7 C8 L2+L1+

22 3BSE056248


The MTU and S800L module (locking screw in position) can be disconnected from the FCI, ModuleBus Modem, another MTU or S800L module by using a screw driver and pressing it between the two items.

Figure 10. Module Release

A

BC

D

E F

A

BC

D

E FSTN. ADDR.

SBSA

L-L+ L+

L-

SH

+

-

F R

T2T1

P

SH

+

-

SHSH

SERVICE

CI810

012

9

75

38

4 6

012

9

75

38

4 6

x 10

x 1

AF100

C1 2 3 4 5 6 7 C8

B1 2 3 4 5 6 7 B8

A1 2 3 4 5 6 7 A8

L1+ L2+

L2-L1-

L2+L1+Tx

Rx

Tx RxSWX.X/Y

21

DO801

3BSE056248 23


I/O Module Installation on Module Termination Unit

Connection of the I/O module to the MTU is made by setting the I/O Module Keys #1 and #2 to the correct setting, place the I/O Module Lock/Switch to the unlock position and then push the I/O module straight onto the MTU. The I/O module is locked and electrically connected to the MTU by the I/O Module Lock/Switch.

Figure 11. MTU Mechanical Keys for I/O Module and Module Lock

ABC

DE FA

BC

DE FI/O Module Key #1

A

BCD

E F

A

BC

D

E F

678910111213141516

FRW

12345

24VDI810

I/O Module Lock/Switch(shown unlocked)

I/O Module Lock/Switch(shown locked)

I/O Module Key #2

Turn clockwise to lock I/O Module

24 3BSE056248


Figure 12. Mounting of I/O module on MTU

At the mounting of a S800 I/O Box on a Termination Unit the following should be observed:

Press the Box straight and right on to stop into the Termination Unit. Above shown angle shall be 0°.

Turn the Locking Device clockwise to its end position. Above shown state with the Locking Device in a position before end position shall not exist for an active module.

Do not turn the I/O Module Lock/Switch counter-clockwise from the unlocked position. This will cause it to break and will make the MTU and the I/O module inoperative.

3BSE056248 25

Power Supply Section 2 Installation

Power SupplyIt is recommended to feed the system components and field equipment from different power supplies. Example of system components are Controllers, Communication Modules, Fieldbus Communication Interfaces and Modulebus Modems, (for instance PM864A, CI854A, CI840A and TB840A). Example of field equipment is transmitters, actuator as well as the field side of the S800 I/O modules (terminals on MTU and S800L marked L+ and L-).

The power supplies can also be configured in a redundant configuration using independent voting units.

Figure 13. Recommended Power Supply Concept

26 3BSE056248

Section 3 Configuration

Controller Configuration - Basic Rules and Examples

Information regarding limitations for the different controllers can be found in IndustrialIT 800xA - Control and I/O, AC 800M Controller Hardware, Hardware and Operation (3BSE036351Rxxxx).

3BSE056248 27

Controller Configuration - Basic Rules and Examples Section 3 Configuration

Single CPU Configuration

28 3BSE056248

Section 3 Configuration Controller Configuration - Basic Rules and Examples

Single CPU with Redundant CI Configuration

3BSE056248 29

Controller Configuration - Basic Rules and Examples Section 3 Configuration

Redundant CPU with Non-Redundant CI Configuration

30 3BSE056248

Section 3 Configuration Controller Configuration - Basic Rules and Examples

Redundant CPU with Redundant CI Configuration

3BSE056248 31

S800 I/O Configuration - Basic Rules and Examples Section 3 Configuration

S800 I/O Configuration - Basic Rules and Examples

Information regarding limitations for the different I/O modules can be found in IndustrialIT, Control and I/O, S800 I/O, General Information and Installation (3BSE020923Rxxxx).

32 3BSE056248

Section 3 Configuration S800 I/O Configuration - Basic Rules and Examples

Non-redundant PROFIBUS Node

In total max 24 modules per CI801 but limited by: • PROFIBUS data capability.• CI801/TB820 Power supply capability.• Required scan cycle time.

Modules not supported:

DI825, DO880, AI880A, DI830, DI831, DI880, DI885.5 Mbit/s ABB Drives and SOE on DI840 are not supported.

3BSE056248 33


Line/Master-redundant PROFIBUS Node

In total max 24 modules per CI840A but limited by: • PROFIBUS data capability.• CI840A/TB820 Power supply capability.• Required scan cycle time.


DI825, DO880, AI880A, DI830, DI831, DI880, DI885.ABB Drives and SOE on DI840 are not supported.

34 3BSE056248


Line/Master-redundant PROFIBUS Node with Redundant I/O

In total max 24 modules per CI840A (a redundant pair is 2 modules) but limited by: • PROFIBUS data capability.• CI840A/TB820 Power supply capability.• Required scan cycle time.


DI825, DO880, AI880A, DI830, DI831, DI880, DI885.ABB Drives and SOE on DI840 are not supported.

3BSE056248 35


Direct I/O to non-redundant AC 800M Controller

In total max 96 modules but limited by:• PM8xx and TB820 Power supply capability.• Required scan cycle time.• Required CPU load.

Supported modules:

DI880, DO880, AI880A are supported if PM865 and TB840A (instead of TB820).The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42.

36 3BSE056248


Direct I/O to redundant AC 800M Controllers

In total max 84 modules but limited by:• TB840A Power supply capability.• Required scan cycle time.• Required CPU load.

Supported modules:

AI880A, DI880, DO880 are supported if PM865.The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42.

3BSE056248 37


Direct redundant I/O to redundant AC 800M Controllers

In total max 42 pairs of modules but limited by:• TB840A Power supply capability.• Required scan cycle time.• Required CPU load.

Supported redundant modules:

DI840, DO840, AI843, AO845, DP840, AI845. AI880A, DI880, DI880 are supported if PM865. The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42. It is possible to mix clusters with and without redundant I/O, but not on the same cluster. See non-redundant I/O for information.

38 3BSE056248


High Integrity I/O to non-redundant High Integrity Controller

In total max 96 modules but limited by:• PM8XX and TB840A Power supply capability.• Required scan cycle time.• Required CPU load.

The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42.

3BSE056248 39


High Integrity I/O to redundant High Integrity Controllers

In total max 84 modules but limited by:• TB840A Power supply capability.• Required scan cycle time.• Required CPU load.

The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42.

NOTE! In a configuration with redundant CPUs, COM3 and the electrical ModuleBus cannot be used.

40 3BSE056248


HI redundant or hot replacement I/O to redundant PM865

In total max 42 pairs of modules but limited by:• TB840A Power supply capability.• Required scan cycle time.• Required CPU load.

Supported modules:

DI840, DO840, AI843, AO845, DP840, DI880, DO880, AI845, AI880A. The optical ModuleBus can be configured for long distances and in star configurations using TB825 see Long distance distribution in star as Direct I/O to AC 800M on page 42. It is possible to mix clusters with and without redundant I/O but not on the same cluster. See non-redundant I/O for information.

3BSE056248 41


Long distance distribution in star as Direct I/O to AC 800M

Calculation of the ModuleBus delay for the configuration in the figure above:ModuleBus delay = (total delay in optical fiber) + 5 x (opto-to-opto delay in TB820) + 2 x (delay in TB825) + (opto-to electrical delay in TB820) = (4 x 15 + 3 x 1.5 + 1000) x 0.01 + 5 x 4 + 2 x 2.4 + 6.5 = 42 s.

42 3BSE056248

Section 4 Operation

Hardware Indicators

AC 800M Controller (PM8xx)

Equipped with Control Software, the basic PM8xx/TP830 hardware units mounted on the AC 800M hardware platform constitute an AC 800M Controller.

LED Indicators

See Figure 2, for description of placement.

Table 1. PM8xx - LED Indicators

Marking Color Function

F(ault) Red Normal state - OFF Re-start (INIT) temporarily lit F(ault).May also be operated by software program

R(un) R(un) Normal state - ON Re-start (INIT) temporarily extinguishes R(un). At restart press the (INIT) push button (3 sec. or more) until R(un) flashes.May also be operated by software program.

P(ower) Green Normal state - ONWhen lit, indicates that the CPU DC/DC converter is generating valid +5 V and +3.3 V DC supply voltages.No software control.

3BSE056248 43

LED Indicators Section 4 Operation

B(attery) Green Normal state - ONLit when internal or external battery voltage is above 3.1 V. The LED is controlled by a software battery voltage test(1).

Tx Yellow Data Transmission(2),

CN1 + CN2 and COM3 + COM4

Flashes in synchronization with Tx traffic

Rx Yellow Data Reception(2), CN1 + CN2 and COM3 + COM4Flashes in synchronization with Rx traffic

Valid for PM8xx in redundant operation

PRIM(ary Yellow Lit in single and redundant configuration.Indicates Primary CPU in redundant configuration. Controlled by software.

DUAL Yellow Lit when the CPU is running in redundant configuration and synchronized state.s

(1) The software performs cyclic battery voltage level tests via a dedicated LED control input. The battery provides back-up power for both the application memory and the real time clock during power down. The battery is either accessible via the PM8xx cover panel or externally connected to the external battery connector. Battery voltage is checked by the software. Voltage is common for both the internal and external battery. For this reason the internal battery should be removed when using the external battery, since having two batteries connected in parallel will result in greatly reduced capacity.

(2) Only CN1 for PM851. Do not connect to CN2

Table 1. PM8xx - LED Indicators (Continued)


44 3BSE056248

Section 4 Operation Switches and Push Buttons

Switches and Push Buttons

Communication Interface LEDs

Table 3 and Table 5 shows Indicators for the communication interface modules.

Table 2. PM8xx - Switches and Push Buttons


INIT Manual Push Button

Initiates1. Cold Restart if INIT is held less than 2.5 seconds.2. Controller Reset if INIT is held more than 3 seconds.If INIT is pushed on the Primary CPU in redundant configuration a switch over to the backup CPU will be initiated.

Table 3. Common LEDs for Communication Interfaces

Marking Color Description

F(Fault) Red Unit error detected

R(Run) Green Operating

Tx/Tx1/Tx2 (Transmit) Yellow Flashes if transmitting

Rx/Rx1/Rx2/RxA/RxB (Receive) Yellow Flashes if receiving

RxTx (Receive &Transmit) Yellow Flashes if transmitting or receiving

3BSE056248 45

S800 I/O Module LEDs Section 4 Operation

S800 I/O Module LEDs

Figure 14 shows examples of front panels for different types of I/O modules. On the front of all I/O modules there are at least three LEDs (FAULT, RUN and WARNING) indicating the module status. Additionally some modules have LEDs indicating OSP or PRIMARY. Each digital channel also has one LED indicating current state (on/off). For more information see the tables below.

• F - The FAULT LED shall indicate when the I/O module detect a fatal error or before first access after power up.

• R - The RUN LED shall indicate when the I/O module is operational.

Table 4. Common LEDs for Communication Interfaces in Redundant operation


PRIM(Primary) Yellow Indicates the primary unit in redundant configuration. (LED is on in both single and redundant configuration).

DUAL Yellow Indicates when unit is running in redundant configuration.

Table 5. Special LEDs

Module Marking Color Description

CI858 Tools Yellow Indicates reception / transmission of data frames on the PC Tool buss.

CI862 Com Error Yellow Indicates traffic.

CI856 TO Yellow Flashes at S100 I/O access time-outs.

46 3BSE056248

Section 4 Operation S800 I/O Module LEDs

• W - The WARNING LED shall indicate when a non-fatal error is detected and the module continues to run.

• O - The OSP LED shall indicate when the I/O module is in OSP state, that is, when the module is commanded to OSP or when automatically set to OSP state due to communication error.

• PRIM - The PRIMARY LED shall indicate when the I/O module is primary (in a redundant pair). In a redundant configuration, the primary module is scanned at the specified cycle time to supply input values to the application, while the backup module is scanned at a low cycle for diagnostic purpose. The input values from the backup module are not used by the application.

Figure 14. Examples of S800 I/O Modules LED Locations

678910111213141516

FRWO12345

678910111213141516

FRW

12345

DO810 DI810

FRWO

FRW

AI810AO810/AO810V2

PX1UP1ST1DI1SY1DO1TP1UL1PX2UP2ST2DI2SY2DO2TP2UL2

FRWO

DP820

3BSE056248 47

S800 I/O Module LEDs Section 4 Operation


F (Fault) Red Internal fault in the module affecting all channels(1)

(1) Modules without self test function: The F-LED will switch on at power up or restart of the module and switch off after the first successful access to the module. Modules with self test function: The F-LED will switch on at power up, restart of the module or when the module goes to Error state. If the module has not gone to Error state it will switch off the F-LED after the first successful access to the module.

R (Run) Green Operational state

W (Warning) Yellow External fault or internal channel error

O (OSP) Yellow OSP state (Outputs Set as Predetermined)

P (Primary Yellow LED indicating that the module is operating as primary in a redundant pair

Channel status Yellow (+red) This LED shows both value (Yellow ON/OFF) and error (red)

Module State Run Fault Warning OSP Primary Channel Status

Init Off On Off Off Off DI On/Off(1), DO Off

(1) The DI signal status for module DI830, DI831, DI880, DI885, DP820 is only OFF0.

Not configured Flashing/Off On/Off(2)

(2) Will be switched off after the first successful access to the module.

On/Off Off Off DI On/Off(1), DO Off

Ready Flashing/Off Off On/Off Off Off DI On/Off, DO Off

Operational On Off On/Off Off On/Off On/Off

OSP On Off On/Off Off On/Off On/Off

Error Off On On/Off Off Off DI On/Off, DO Off

48 3BSE056248

Section 4 Operation S800L I/O Module LED

S800L I/O Module LED

Figure 15 shows examples of front panels for different types of I/O modules. On the front of each I/O module there is one LED indicating the module status. See the tables below for information on the meaning and indications for these modules. For modules with special LED indications see respectively module in Appendix A, IndustrialIT System 800xA AC 800M Controller - Data Sheet.

The LED shall indicate:

• Red when the I/O module detect a fatal error or before first access after power up.

• Green when the I/O module is operational.

Each digital channel has one LED indicating current state (on/off).

3BSE056248 49

S800L I/O Module LED Section 4 Operation

Figure 15. Example of S800L I/O Module LED Locations

AI8010(4)...20 mA

L+ L- 24 V

DO80124 V 0.5 A

L+ L- 24 V

STA

TU

S

STA

TU

S

S 1 2 14 161312 15111093 4 5 6 7 8

1 2 14 161312 15111093 4 5 6 7 81 87652 3 4+ I + I + I + I + I + I + I + I+ I

S

50 3BSE056248

Section 4 Operation S800L I/O Module LED


S(Status) Red Fault in the module(1)

(1) Modules without self test function, for example, DI/DO modules: The S-LED will switch on to red at power up or restart of the module and switch off after the first successful access to the module. Modules with self test function for example, AI/AO modules: The S-LED will switch on to red at power up, restart of the module or when the module goes to Error state. If the module has not gone to Error state it will switch off the S-LED after the first successful access to the module.

Green Operational state

Module State Status Channel Status

Init Red Off

Not configured Red/Off(1)

(1) Will be switched off after the first successful access to the module.

Off

Ready Off DI On/Off, DO Off

Operational Green On/Off

OSP Green On/Off

Error Red DI On/Off, DO Off

3BSE056248 51

Start Modes Section 4 Operation

Start ModesThe controller may be started with the following start modes:

Warm init

• Power Off / On with a battery backed up CPU.

• Applications restart with retain values.

Cold init

• Press init <2.5 s.

• Applications restart with cold retain values.

Reset

• Press init >3 s or until RUN lead flashes.

• Applications are deleted in controller.

52 3BSE056248

Section 5 Maintenance/Replacement ofFaulty Units

Online Replacement of UnitReplacement online entails adding or removing units in a controller without disturbing the execution of the running application program. Units are connected to the CEX-Bus and the electrical ModuleBus (S800 I/O).

CEX-Bus

Communication interfaces () Can be removed or replaced online

Restrictions apply; refer to the installation section for each interface.

Base plates for CI8xx (TP8xx) It is not allowed to manipulate CEX bus base plates in a powered and running system. Before changing or removing a base plate, all CEX modules on that segment must be removed.

ModuleBus

S800 I/O units Can be removed or replaced online. (Not S800L)

Module Terminal Units (MTUs) Must not be replaced online

Redundant CPUs

Processor unit Can be removed or replaced online by following a specified sequence (see the next following pages)

3BSE056248 53

Online Replacement of Unit Section 5 Maintenance/Replacement of Faulty Units

54 3BSE056248

Pu

HC

Cf

Appendix A IndustrialIT System 800xAAC 800M Controller - Data Sheet

CP

Us/

Fea

ture

s

PM

851

PM

856

PM

860

PM

861A

PM

864A

PM

865

PM

866

rocessor nit

PM851K01 incl: 1 PM851 CPU and required optional items



PM861AK01 incl: 1 PM861A CPU and required optional items PM861AK02 incl: 2 PM861A CPUs and required optional items




igh Integrity ontroller

No No No No No Yes together with SM81x

No

lock requency

48 MHz 48 MHz 48 MHz 48 MHz 96 MHz 96 MHz 133 MGHz

3BSE056248 55

Appendix A IndustrialIT System 800xA AC 800M Controller - Data Sheet

M(

Crs

PR

Cpap

CmC

IoM

EcCN

D

emory RAM)

8 Mb 8 Mb 8 Mb 16 Mb 32 Mb 32 Mb 64 Mb

PU edundancy upport

No No No Yes Yes Yes Yes

erformance elation

1.0 ms 1.0 ms 2.0 ms 2.0 ms 3.1 ms 3.1 ms 4.3 ms

ycle time er pplication rograms

Down to 1 ms

omm. odules on EX bus

1 12 12 12 12 12 12

/O capacity n oduleBus

modulesmax 24 I/O

modulesmax 96 I/O

modulesmax 96 I/O

modulesmax 96 I/O(84 in redundant configur-ation)

modulesmax 96 I/O

(84 in redundant configur-ation)

modulesmax 96 I/O


modulesmax 96 I/O


thernet hannels for ontrol etwork

1 2 2 2 2 2 2

imensions W 119 x H 186 x D 135 mm (4.7 x 7.3 x 5.3 in.)

CP

Us/

Fea

ture

s

PM

851

PM

856

PM

860

PM

861A

PM

864A

PM

865

PM

866

56 3BSE056248


IEC

618

50

Mod 8

Prot 50

Masslav

Numchan

Maxon Cbus

Cabreduancy

Su

pp

ort

ed

Co

mm

un

icat

ion

mo

du

les

PR

OF

IBU

S

Fo

un

dat

ion

Fie

ldb

us

RS

-232

C

MB

300

INS

UM

Dri

veb

us

S10

0 I/O

inte

rfac

e

TR

IO I/

O

Sat

t I/O

Mo

db

us

TC

P

ule CI854A CI860 CI853 CI855 CI857 CI858 CI856 CI862 CI865 CI867 CI86

ocol DP-V1(PA via Linking Device)

HSE (H1 via Linking Device)

Modbus master, Comli- master/slave, Siemens master, User defined protocols

MB300 IEEE 802.3

Drive-bus

S100 I/O

Trio I/O Satt I/O Mod-bus TCP

IEC618

ter or e

master master master/slave

master/slave

master master master master master master/slave

n/a

ber of nels

1 1 2 2 1 1 main,2 aux

1 1 1 1 10/100Mbps

1 10

Mbps

1

units EX

12 6 12 12 6 2 12 4 4 12 4

le nd-

yes no no yes no no no no no no no

3BSE056248 57


Modreduancy

Dimsion

IEC

618

50

ule nd-

yes yes no no no no no no no yes no

en-s

W 58 x H 186 x D 135 mm (2.3 x 7.3 x 5.3 in.)

Su

pp

ort

ed

Co

mm

un

icat

ion

mo

du

les

PR

OF

IBU

S

Fo

un

dat

ion

Fie

ldb

us

RS

-232

C

MB

300

INS

UM

Dri

veb

us

S10

0 I/O

inte

rfac

e

TR

IO I/

O

Sat

t I/O

Mo

db

us

TC

P

58 3BSE056248

Appendix B System 800xA S800 I/O System -Data Sheet

General specifications

Power supply 24V d.c. (19.2 - 30V)

Temperature range 0...55°C (non-condensing)(1)

Protection class IP20

Standards complied with:

- Electrical safety

- Hazardous locations (Class1 Zone 2 and Class 1 Division 2)

- Corrosive gases

EN 3810, EN 50178, IEC 61131-2, UL508, CSA 22.2 No. 142-M1987

No. 213-M1987, FM 3600, FM 3611, UL 60079-15, CSA 22.2 No.213-M1987 CAN/CSA-E60079-15:02

ISA Class G2 or G3 (ISA-71.04)

Insulation test voltage 500/2000V a.c.

Communication media

Profibus DP Twisted pair screened/fiber-optic cable. Up to 99 stations per bus. Up to 32 per twisted-pair segment. Bus length: Up to 1200m (3937ft.) per twisted-pair segment.

Communication interfaces

CI801 For PROFIBUD-DP/V1. Hot Configuration In Run & HART® pass-through. GSD-file provided.

3BSE056248 59

Appendix B System 800xA S800 I/O System - Data Sheet

TB820/825/842 Optical cluster modem/ports for ModuleBus/drives integration.

CI840A For redundant PROFIBUS-DP/V1. Hot Configuration in Run & HART® pass through. GSD file provided.

TB840A Optical cluster modem for redundant or single ModuleBus. Installed on TU807/TU840/TU841/TU848/TU849. Used with AC 800M.

Module Termination Units (MTU:s)

Compact, 50V applications

TU810

TU812

TU814

With screw terminals.

With 25 pin D-sub connector.

With 3 crimp snap-in connectors.

Compact, 250V applications

TU811

TU813

With screw terminals.

With 3 crimp snap-in connectors.

Compact for intrinsic safety

TU89X With screw terminals & isolated power supply.

Extended, 50V applications

TU830/TU835/TU838/TU850

TU833

TU834

With screw terminal, pwr. distribution & fuse.

With spring-cage term., pwr distribution & fuse.

With screw terminals for shunt sticks.

Extended, 250V applications

TU831/TU836/TU837/TU839 With screw terminals, pwr. distribution & fuse.

Redundancy, 50V applications

TU842/843

TU844/845

(horiz./vert. mounting) With screw terminals.

(horiz./vert. mounting) With screw terminals and shunt stick, TY80X.

Terminal UnitTU805

For DI801 & DO801. With field power distribution screw terminals.

60 3BSE056248


S800 I/O modules

Digital input modules

DI810 16 channels, 2 groups of 8 ch., 24V d.c., current sink.

DI811 16 channels, 2 groups of 8 ch., 48V d.c., current sink.

DI814 16 channels, 2 groups of 8 ch., 48V d.c., current source.

DI820 8 channels, separate returns, 110V d.c., 120V a.c.

DI821 8 channels, separate returns, 220V d.c., 230V a.c.

DI825 With time tagging. 8 channels, sep. returns, 125V d.c.

DI830 With time tagging. 16 channels, 2 groups of 8 channels, 24V d.c., current sink. Resolution: <0.5ms.

DI831 With time tagging. 16 channels, 2 groups of 8 channels, 48V d.c., current sink. Resolution: <0.5ms.

DI885 With time tagging. 8 channels, common return, 24-48V d.c. current sink. Time tagging resolution: 1ms.

Pulse input module

DP820 2 channels, separate returns, 0.25Hz -1.5MHz, signal voltage: 5 / 24V d.c.

Digital output modules

DO810 16 channels, 2 groups of 8 channels, 24V, max 0.5A d.c., transistor, current source, short-circuit-proof.

DO814 16 channels, 2 groups of 8 channels, 24V d.c., max 0.5A, transistor, current sink, short-circuit-proof.

DO815 8 channels, 2 groups of 4 channels, 24V d.c., max 2A, transistor, current source, short-circuit-proof.

DO820 8 channels, separate returns, 5-250V, max 3A a.c./d.c., relay (N.O.).

3BSE056248 61


DO821 8 channels, separate returns, 5-250V, max 3A a.c./d.c., relay (N.C.).

Analog input modules

AI810 8 channels, single-ended, 0(4)-20mA, 0(2)-10V, 12bits.

AI815 8 channels, common return, 0(4)-20mA, 0(1)-5V, HART

AI820 Differential inputs, 4 channels, 0(1)-5V, ±0(2)-10V, ±0(4)-20mA, 14 bits+sign.

AI825 Galvanically isolated, 4channels, ±0(2)-10V, ±0(4)-20mA, 14 bits+sign.

AI830A RTD inputs, 8 channels Pt100, Ni100, Ni120, Cu10, resistor 0-400Ω, 14 bits, 3-wire.

AI835A TC inputs, 8 channels, (7+ ref. junction), separate returns, TC types B, C, D, E, J, K, L, N, R, S, T, U,-30...75mV, 15 bits.

Analog output modules

AO810V2 8 channels, common return, 0(4)-20mA, 14 bits, load: 850Ω (short-circuit-proof).

AO815 8 channels, common return, 4-20mA, HART

AO820 Isolated output, 4 channels, separate returns, measuring range: ±0(2)-10V, ±0(4)-20mA, resolution:12 bits + sign, load: ≤500Ω (current) ≥2kΩ (voltage), short-circuit-proof.

S800 I/O modules for redundancy & SIL3

DI840 16 channels, common return, 24V d.c., current sink, extended diagnostics.

DI880 16 channels, 24V d.c., current sink, SIL3, extended diagnostics.

DP840 8 channels, separate returns, freq. measurement or pulse counting, 0.5-20kHz, 12/24V d.c. or NAMUR.

62 3BSE056248


DO840 16 channels, common return, 24V d.c., max 0,5A, current source, short-circuit-proof, extended diagnostics.

DO880 16 channels, 24V d.c., max. 0.5A, current source, SIL3, short-circuit-proof, extended diagnostics.

AI843 TC input, 8 channels + ref. junction, TC types: B, C, E, J, K, L, N,R, S, T, U, -30...75mV, 16 bits, extended diagnostics.

AI845 8 channels, common return, 0(4)-20mA 0(1)-5V, extended diagnostics, HART support.

AI880A 8 channels, common return, 0(4)-20mA, SIL3, extended diagnostics, HART support.

AO845A 8 channels, common return, 4.20mA, extended diagnostics, HART support.

S800L I/O modules

DI801 16 channels, 1 group, 24V d.c., current sink.

DI802 8 channels, 110V d.c., 120V a.c.

DI803 8 channels, 220V d.c., 230V a.c.

DO801 16 channels, common return, 24V, max 0.5A d.c., transistor, current source, short-circuit-proof.

DO802 8 channels, 5-250V, max 2A a.c./d.c., relay (N.O).

AI801 8 channels, single-ended, 0(4)-20mA, 12 bits.

AO801 8 channels, common return, 0(4)-20mA, 12 bits, load: <750Ω.

I/O modules with intrinsic-safety interface

DI890 8 channels, separate returns, 24V d.c. current sink, with wire-fault detection

DO890 4 channels, separate returns, load 150-5000Ω, 11V @ 40mA, current source, short-circuit-proof, with wire-fault detection.

3BSE056248 63


AI890 8 channels, single-ended, 0(4)-20mA, 12 bits, transmitter power supply.

AI893 8 channels, TV 7 + ref. junction, separate returns,TC types B, C, E, J, K, L, N, R, S, T, U, -10...80mV, RTD: Pt50-1000, Ni100-500, Cu10-100, resistor 0-4000Ω, 3-wire, 15 bits + sign., TC/RTD inputs.

AI895 8 channels, single-ended, 4-20mA, 12 bits, transmitter power supply, HART interface.

AO895 8 channels common return, 0(4)-20mA, 12 bits,load: 750Ω (short-circuit-proof), wire-fault detection

AO895 8 channels, common return, 4-20mA, 12 bits,load: 750Ω (short-circuit-proof), HART interface & wire-fault detection.

(1) Approvals are issued for +5 to +55°C.

64 3BSE056248

Appendix C Dimensions

Redundant Comm. Modules Extended I/O

Compact I/O

Intrinsic safety I/O

Communication Interface

CPU

Redundant I/O

CI801, S800L I/O

3BSE056248 65

Appendix C Dimensions

66 3BSE056248

3BSE056248Copyright © 2003-2009 by ABB. All Rights Reserved® Registered Trademark of ABB.™ Trademark of ABB.

Automation Technology Products Wickliffe, Ohio, USAwww.abb.com/controlsystems

Automation Technology ProductsVästerås, Swedenwww.abb.com/controlsystems

http://www.abb.com

3bse056248 en Ac 800m and s800 i o - Getting Started

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